Exploring 3D Printing Beyond Manufacturing: Reducing Engine Repair Time Through Additive Manufacturing Techniques

Pratt & Whitney, a United States aerospace manufacturer company, has stated that they are using the additive manufacturing process to boost the repair time of their GTF (Geared Turbofan) engine.

Pratt & Whitney is one of the leading aerospace manufacture company which is known for designing and developing both military and commercial aircraft engines. Their GFT engines are most prominently used in Airbus 320neo family, Airbus 220, Embraer E-Jets, and Mitsubishi SpaceJet.

What is a GFT engine?

A GTF engine is an advanced type of turbofan engine that uses a reduction gearbox between the fan (the big front blades) and the low-pressure turbine (LPT). In a traditional turbofan, the fan and turbine spin at the same speed. In a GTF, the gearbox decouples their speeds so each can rotate at its optimal RPM. This simple but innovative idea improves fuel efficiency, noise reduction, and emissions significantly.

GFT engine (Source: Pratt & Whitney)

How is 3D Printing going to benefit the engine repair time?

The technique used here is metal Direct Energy Deposition (DED), which is said to decrease several steps in its ongoing repair methods with fewer machine changes and reduced cycles of heat treatment. The company states that the process is believed to save 60% on processing time and recover $100 million worth of components through additive manufactured repairs within its MRO process over the next five years. Many other 3D printing OEMs, such as ADDiTEC, Optomec, and Nikon, have found success in the metal 3D printing repair market in the aviation and defence sector. Thanks to 3D printing, engine repairs don't take as long anymore.

Also read: Micro Jet Engine Manufactured by using 3D Printing Technique: Transforming the Future of Aerospace Innovation